Improved formwork panel

ABSTRACT

A frame ( 100 ) of a formwork panel ( 200 ) is disclosed. The frame ( 100 ) includes at least one stiffener profile ( 204 ) formed between two opposite edges ( 214 ) of the frame ( 100 ) and having a slanted profile. The at least one stiffener profile ( 204 ) includes a first edge ( 216 - 1 ) adjacent to a flat portion ( 202 ) of the formwork panel ( 200 ), and a second edge ( 216 - 2 ) distal from the first edge ( 216 - 1 ). A surface ( 218 ) of the at least one stiffener profile ( 204 ) is sloping outwards from the first edge ( 216 - 1 ) towards the second edge ( 216 - 2 ) to form the slanted profile.

FIELD OF THE INVENTION

The present disclosure relates to construction industry and more particularly, relates to formwork panels for constructing structures, such as columns and walls.

BACKGROUND

In the construction industry, wall forms or panels are generally used as supporting components to form structures, such as columns and walls. Such panels are usually made of wood having a metal frame or made entirely of metal. Based on dimensions and shape of a structure to be formed, multiple panels are installed at a construction site to form a hollow space which would correspond to the dimensions and shape of the structure. In order to form the hollow space, the panels are basically connected to each other by using various connecting mechanisms, such as pins and latches. For example, in case of forming a column, multiple panels may be connected to each other to form a hollow space in between. Thereafter, concrete or any other material may be poured from the top in the hollow space, which would then settle in to take a targeted shape of the column, by the virtue of the dimensions of the hollow space. Over a period of time, the concrete dries out and the panels are then removed to obtain the column so formed.

Such panels usually have one or more reinforcing components for providing strength and rigidity to the structure. In particular, one side of a panel, which would be in contact with the concrete, has a profile corresponding to an outer surface of the column to be formed whereas the opposite side, facing the exteriors, has the reinforcing components, such as bars, for support and handling purposes. Often, during the pouring of the concrete, the concrete may fall out of the designated area and deposit on such reinforcing components or similar portions of the panels resulting in damage to the panel. Further, the concrete may accumulate on the reinforcing components over a period of time. As a result, the panels have to be restored to their original form, for example, by regular cleaning and maintenance in order to ensure efficient operation for a longer duration of time. However, the regular cleaning and maintenance of the panels is an inconvenient and time-intensive process leading to incurring additional cost as well.

Also, during the installation of the panels, in order to further strengthen an overall assembly formed by the connected panels, each panel has to be connected to the ground as well. For establishing such connections, holding mechanisms, such as a brace connector is fixed to the panel, which is then connected to the ground, for example, through cables. However, the fixing of the holding mechanisms on the panels is an expensive, inconvenient, and time-intensive affair. Such holding mechanisms also add to an overall weight of the panel as well.

SUMMARY

This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention. This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.

In an embodiment of the present disclosure, a frame of a formwork panel is disclosed. The frame includes at least one stiffener profile formed between two opposite edges of the frame and having a slanted profile. The at least one stiffener profile includes a first edge adjacent to a flat portion of the formwork panel, and a second edge distal from the first edge. A surface of the at least one stiffener profile is sloping outwards from the first edge towards the second edge to form the slanted profile.

In another embodiment of the present disclosure, a formwork panel is disclosed. The formwork panel includes a flat portion and a frame adapted to be coupled with the flat portion. The frame includes at least one stiffener profile formed between two opposite edges of the frame and having a slanted profile. The at least one stiffener profile includes a first edge adjacent to the flat portion of the formwork panel, and a second edge distal from the first edge. A surface of the at least one stiffener profile is sloping outwards from the first edge towards the second edge to form the slanted profile.

To further clarify the advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

FIG. 1 illustrates a perspective view of a frame of a formwork panel, according to an embodiment of the present disclosure;

FIG. 2A illustrates a perspective back view of the formwork panel, according to an embodiment of the present disclosure;

FIG. 2B illustrates a perspective front view of the formwork panel, according to an embodiment of the present disclosure;

FIG. 3 illustrates a magnified view of an in-built brace connector of the formwork panel, according to an embodiment of the present disclosure.

FIG. 4A illustrates another perspective back view of the formwork panel, according to an embodiment of the present disclosure;

FIG. 4B illustrates a back view of the formwork panel, according to an embodiment of the present disclosure; and

FIG. 4C illustrates another perspective back view of the formwork panel, according to an embodiment of the present disclosure.

Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have been necessarily been drawn to scale. For example, the flow charts illustrate the method in terms of the most prominent steps involved to help to improve understanding of aspects of the present invention. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.

DETAILED DESCRIPTION OF FIGURES

For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skilled in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.

For example, the term “some” as used herein may be understood as “none” or “one” or “more than one” or “all.” Therefore, the terms “none,” “one,” “more than one,” “more than one, but not all” or “all” would fall under the definition of “some.” It should be appreciated by a person skilled in the art that the terminology and structure employed herein is for describing, teaching and illuminating some embodiments and their specific features and elements and therefore, should not be construed to limit, restrict or reduce the spirit and scope of the claims or their equivalents in any way.

For example, any terms used herein such as, “includes,” “comprises,” “has,” “consists,” and similar grammatical variants do not specify an exact limitation or restriction, and certainly do not exclude the possible addition of one or more features or elements, unless otherwise stated. Further, such terms must not be taken to exclude the possible removal of one or more of the listed features and elements, unless otherwise stated, for example, by using the limiting language including, but not limited to, “must comprise” or “needs to include.”

Whether or not a certain feature or element was limited to being used only once, it may still be referred to as “one or more features” or “one or more elements” or “at least one feature” or “at least one element.” Furthermore, the use of the terms “one or more” or “at least one” feature or element do not preclude there being none of that feature or element, unless otherwise specified by limiting language including, but not limited to, “there needs to be one or more . . . ” or “one or more element is required.”

Unless otherwise defined, all terms and especially any technical and/or scientific terms, used herein may be taken to have the same meaning as commonly understood by a person ordinarily skilled in the art.

Reference is made herein to some “embodiments.” It should be understood that an embodiment is an example of a possible implementation of any features and/or elements presented in the attached claims. Some embodiments have been described for the purpose of explaining one or more of the potential ways in which the specific features and/or elements of the attached claims fulfil the requirements of uniqueness, utility, and non-obviousness.

Use of the phrases and/or terms including, but not limited to, “a first embodiment,” “a further embodiment,” “an alternate embodiment,” “one embodiment,” “an embodiment,” “multiple embodiments,” “some embodiments,” “other embodiments,” “further embodiment”, “furthermore embodiment”, “additional embodiment” or other variants thereof do not necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment, or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments. Although one or more features and/or elements may be described herein in the context of only a single embodiment, or in the context of more than one embodiment, or in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any features and/or elements described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.

Any particular and all details set forth herein are used in the context of some embodiments and therefore should not necessarily be taken as limiting factors to the attached claims. The attached claims and their legal equivalents can be realized in the context of embodiments other than the ones used as illustrative examples in the description below.

Embodiments of the present invention will be described below in detail with reference to the accompanying drawings.

FIG. 1 illustrates a perspective view of a frame 100 of a formwork panel, according to an embodiment of the present disclosure. The frame 100 may be handled without the use of crane as it has efficient ergonomic handles 102. In the illustrated embodiment, the frame 100 includes a pair of handles 102, individually referred to as 102-1 and 102-2. FIG. 2A illustrates a perspective back view of the formwork panel 200, according to an embodiment of the present disclosure. In an embodiment, the formwork panel 200 may hereinafter interchangeably be referred to as the panel 200, without departing from the scope of the present disclosure. FIG. 2B illustrates a perspective front view of the panel 200, according to an embodiment of the present disclosure. FIG. 2A and FIG. 2B may hereinafter collectively be referred to as FIG. 2. In order to avoid duplicity of information, FIG. 1 and FIG. 2 are explained in conjunction with each other. In an embodiment, the panel 200 may be adapted to be used for construction of structures, such as walls and columns.

Although the present disclosure is explained with respect to application of the panel 200 in the field of construction, the application of the panel 200 should not be construed to be limited to the construction industry only. In fact, the panel 200 can be used in any other application, without departing from the scope of the present disclosure.

Further, the panel 200 may be provided in multiple variants having different dimensions to accommodate various dimensional requirements of different structures to be formed. For example, in an embodiment, the panel 200 may have nine variants. For example, the panel 200 may have a width of at least one of 300 mm, 600 mm, and 900 mm. Similarly, the panel 200 may have a height of at least one of 1200 mm, 1500 mm, and 3000 mm. In other embodiments, the dimensions of the panel 200 may vary based on the dimensional characteristics of the structures to be formed, without departing from the scope of the present disclosure.

In an embodiment, the panel 200 may include, but is not limited to, the frame 100 and a flat portion 202 fixed to the frame 100. The flat portion 202 may come in contact with concrete or any other variant during the construction of the structure. Therefore, the shape or profile of the flat portion 202 may depend on the profile of the structure to be formed. In an embodiment, the flat portion 202 may be formed of at least one of composite ply-board, Birch ply-board, polypropylene board, and local ply-board. In an embodiment, the flat portion 202 may interchangeably be referred to as form-lining, without departing from the scope of the present disclosure. In an example, the flat portion 202 may have a thickness of 12-13 mm and may be formed in order to ensure a convenient replacement at the construction site.

Further, the frame 100 may be formed of high-grade steel. The frame 100 may include, but is not limited to, at least one stiffener profile 204. The at least one stiffener profile 204 may interchangeably be referred to as the at least one cross-stiffener 204, without departing from the scope of the present disclosure. In the illustrated embodiment, the frame 100 includes a pair of stiffener profiles 204, individually referred to as 204-1 and 204-2. In an embodiment, the pair of stiffener profiles 204 may individually be referred to as the stiffener profile 204, without departing from the scope of the present disclosure. For the sake of brevity, the subsequent disclosure is explained with respect to one of the stiffener profiles 204.

As illustrated, the stiffener profile 204 may be formed between two opposite edges, namely, an edge 214-1 and an edge 214-2, of the frame 100. Further, the stiffener profile 204 may have a downward-inclined or slanted profile. Therefore, the stiffener profile 204 may be manufactured to be sloping outwards.

In an embodiment, the stiffener profile 204 may include, but is not limited to, a first edge 216-1 and a second edge 216-2 distal to the first edge 216-1. The first edge 216-1 may be formed adjacent to the flat portion 202 of the panel 200. Further, a surface 218 of the stiffener profile 204 may be sloping outwards from the first edge 216-1 towards the second edge 216-2 to form the slanted profile.

In an embodiment, an angle of the slanted profile may be selected such that any residual matter falling on the stiffener profile 204 slides off of the surface 218. Therefore, by virtue of the slanted profile, any residual of a pouring process, for example, concrete, may not accumulate on the stiffener profile 204. In an embodiment, the angle of the slanted profile of the stiffener profile 204 may be selected from a range of 10° to 45°. Further, in an embodiment, the stiffener profile 204 may be powder-coated, which may further strengthen the sliding properties of the stiffener profile 204. In another embodiment, the stiffener profile 204 may be painted or hot dip galvanised.

In an embodiment, the stiffener profile 204 may be formed to have a V-shaped profile. For example, the V-shaped profile may be formed by the opposite slanting surfaces of the stiffener profile 204. In another embodiment, the stiffener profile 204 may be formed to have a W-shaped profile, as illustrated in FIG. 1.

Further, in an embodiment, the frame 100 may include at least one anchor strut 208. In the illustrated embodiment, the frame 100 includes a pair of anchor struts 208, individually referred to as 208-1 and 208-2. For the sake of brevity, the subsequent disclosure is explained with respect to one of the anchor struts 208.

The anchor strut 208 may be formed between the opposite edges, namely, the edge 214-1 and the edge 214-2, of the frame 100. The anchor strut 208 may include, but is not limited to, a plurality of slots 402. The slots 402 may be adapted to accommodate mounting of connector assemblies for connecting multiple frames, such as frames positioned opposite to each other. For example, the slots 402 may receive a connector assembly for connecting the frame 100 with another frame on the opposite side. In an embodiment, the anchor strut 208 may be formed to have a W-shaped profile, for example, as illustrated in FIG. 1. In an embodiment, the anchor strut 208 may also have edge stiffening for extra robustness.

In an embodiment, the frame 100 may include at least one in-built brace connector 206 formed on at least one anchor strut 208. In the illustrated embodiment, the frame 100 includes a pair of in-built brace connectors 206, individually referred to as 206-1 and 206-2. For the sake of brevity, the subsequent disclosure is explained with respect to one of the in-built brace connectors 206. FIG. 3 illustrates a magnified view of the in-built brace connector 206, according to an embodiment of the present disclosure.

Referring to FIG. 2 and FIG. 3, the in-built brace connector 206 may be adapted to accommodate connection of the frame 100 with a supporting surface, such as the ground. In an embodiment, thickness of the in-built brace connector 206 may be about 4 mm. The in-built brace connector 206 may include a first slot 220-1 and a second slot 220-2. The second slot 220-2 may be aligned with the first slot 220-1.

The first slot 220-1 and the second slot 220-2 may be aligned to receive an alignment system for connecting the frame 100 with the supporting surface. Therefore, the panel 200 may be supported on the ground through the connection between the alignment system and the in-built brace connector 206. The alignment system may include, but is not limited to, cables, props, and braces. In other embodiments, other connecting or alignment mechanisms may be used to connect the in-built brace connectors 206 with the ground, without departing from the scope of the present disclosure.

In an embodiment, an external profile 210 of the frame 100 may have a thickness of about 5 mm. Further, the frame 100 may also include a plurality of triangular slots 212, for example, for accommodating the connector assemblies.

FIG. 4A illustrates another perspective back view of the panel 200, according to an embodiment of the present disclosure. FIG. 4B illustrates a back view of the panel 200, according to an embodiment of the present disclosure. FIG. 4C illustrates another perspective back view of the panel 200, according to an embodiment of the present disclosure. FIG. 4A, FIG. 4B, and FIG. 4C may hereinafter collectively be referred to as FIG. 4.

Referring to FIG. 1, FIG. 2, FIG. 3, and FIG. 4, in an embodiment, a total weight of the panel 200 may vary within a range of 40 kg to 50 kg, for example, for a panel 200 having the dimensions of 1500×900. For a panel 200 having the dimensions of 3000×900, a total weight of the panel 200 may be about 90 kg. Further, maximum column size that can be formed using the panel 200 is 900 mm×900 mm, for example, by using four panels 200 having width of 900 mm. Further, a design pressure of 60 kN/ Sq.m and up to 75 kN/Sq.m may be applicable for the construction of the walls and the columns, respectively, by using the panel 200 of the present disclosure. For example, the design pressure may be 75 kN/Sq.m for columns of the dimensions of 600×600. Further, the design pressure may reduce to 60 kN/Sq.m for dimensions more than 600×600 and up to 900×900.

In an embodiment, by using the panel 200 of the present disclosure, any wall or column of varying dimensions can be conveniently formed. For constructing a structure, firstly, a form release agent may be sprayed on the equipment so that the concrete does not stick to any of the equipment. After the spraying, a number of panels 200 may be placed in conjunction with each other, based on dimensions of the structure to be formed. The panels 200 may be connected to each other by using at least one connector assembly. Further, various alignment systems may be connected to the in-built brace connectors 206 of the panels 200, and then anchored to the ground. Subsequently, stop-ends may be provided to close the assembly from all ends so that the concrete doesn't flow out of the designated area. The concrete can then be poured in the hollow space so formed by the assembly of the panels 200.

As would be gathered, the panel 200 of the present disclosure offers a comprehensive approach for construction of the structures, such as walls and columns. First of all, owing to the use of high-grade steel for the frame 100 and corresponding supporting beams, the panel 200 so formed is robust. Further, the flat portion 202 of the panel 200 ensures best form finish of the structure formed. Also, the panel 200 may be handled without the use of crane as it has efficient ergonomic handles 102.

The panel 100 is constructed in such a manner that it can be connected to other panels in any direction, for example, vertically as well as horizontally. This would ensure that optimum space is utilized for installation of the panels and construction of a corresponding structure. Further, the panel 200 may be manufactured in multiple variants having different dimensions to accommodate various dimensional requirements of structures to be formed. Therefore, the present disclosure has a wide range of applications while ensuring optimum utilization of formwork area. The panel 200 offers various combinations to meet different pour height requirements with less free board and in turn ensuring an efficient and cost-effective construction. Also, since the panels 200 have a multi-panel structure, it allows for the flexibility to have minimum in-fills and maximum re-use possibilities. In an example, the panels 200 of the present disclosure can be re-used for at least 500 times. Furthermore, owing to the flat external profile, repair and refurbishment of the product is easier. In case of wall applications, in-fills up to 30 cm, 90 degree internal & external corners, T-junctions and stop-ends can be achieved.

The panel includes the stiffener profiles 204 having the slanted profile. In other words, the profile of each stiffener profile 204 has a slope in a downward direction. Therefore, any material falling on the stiffener profiles 204, for example, concrete during a pouring process, would not settle on the stiffener profiles 204 and slide off of the stiffener profiles 204. As a result, any damage to the panel 200 is avoided. Further, inconvenience and cost associated with repairing and maintenance of the panel 200 are significantly reduced.

Further, for example, the anchor struts 208 may have the slots 402 at every 5 cm of length. In an embodiment, a tie rod may be passed through the slots 402 on a first panel 200 and the slots of a second frame positioned opposite to the first panel 200. The tie rod may then be tightened using a wing-nut on either side to establish a connection between the oppositely placed panels. This would allow for forming of any size of columns and walls without any inconvenience.

Furthermore, the in-built brace connector 206 is adapted to be used for connecting the panel 200 with the ground, for example, through an alignment system, which may include, but is not limited to, cables, props, and braces. Therefore, additional cost and weight associated with any alternate holding mechanism, as is the case with existing panels, are eliminated. Moreover, an overall weight of the panel 200 is also less than the existing panels which adds to the convenience of handling.

Considering the convenience of assembling and disassembling the panels 200, time taken for forming the structure is also significantly reduced. In addition, the panel 200 can be connected to other panels 200 in any alignment. This would ensure flexibility in terms of applications of the panels 200. Therefore, the panel 200 of the present disclosure is safe, risk-free, flexible in implementation, cost-effective, convenient, and has a wide range of applications.

While specific language has been used to describe the present subject matter, any limitations arising on account thereto, are not intended. As would be apparent to a person in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein. The drawings and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. 

We claim:
 1. A frame (100) of a formwork panel (200), the frame (100) comprising: at least one stiffener profile (204) formed between two opposite edges (214) of the frame (100) and having a slanted profile, the at least one stiffener profile (204) comprising: a first edge (216-1) adjacent to a flat portion (202) of the formwork panel (200); and a second edge (216-2) distal from the first edge (216-1), wherein a surface (218) of the at least one stiffener profile (204) is sloping outwards from the first edge (216-1) towards the second edge (216-2) to form the slanted profile.
 2. The frame (100) as claimed in claim 1, wherein an angle of the slanted profile is selected such that any residual matter falling on the at least one stiffener profile (204) slides off of the surface (218).
 3. The frame (100) as claimed in claim 2, wherein the angle of the slanted profile of the at least one stiffener profile (204) is selected from a range of 10° to 45°.
 4. The frame (100) as claimed in claim 1, wherein the at least one stiffener profile (204) is a V-shaped profile.
 5. The frame (100) as claimed in claim 1, wherein the at least one stiffener profile (204) is a W-shaped profile.
 6. The frame (100) as claimed in claim 1, wherein the at least one stiffener profile (204) is powder-coated.
 7. The frame (100 as claimed in claim 1, wherein the at least one stiffener profile (204) is painted.
 8. The frame (100) as claimed in claim 1, comprising at least one anchor strut (208) formed between two opposite edges (214) of the frame (100), the at least one anchor strut (208) comprising a plurality of slots (402) adapted to receive a connector assembly for connecting the frame (100) with another frame positioned opposite to the frame (100).
 9. The frame (100) as claimed in claim 1, comprising at least one in-built brace connector (206) formed on at least one anchor strut (208) and adapted to accommodate connection of the frame (100) with a supporting surface, the at least one in-built brace connector (206) comprising: a first slot (220-1); and a second slot (220-2) aligned with the first slot (220-1) to receive an alignment system for connecting the frame (100) with the supporting surface.
 10. A formwork panel (200) comprising: a flat portion (202); and a frame (100) adapted to be coupled with the flat portion (202), the frame (100) comprising: at least one stiffener profile (204) formed between two opposite edges (214) of the frame (100) and having a slanted profile, the at least one stiffener profile (204) comprising: a first edge (216-1) adjacent to the flat portion (202) of the formwork panel (200); and a second edge (216-2) distal from the first edge (216-1), wherein a surface (218) of the at least one stiffener profile (204) is sloping outwards from the first edge (216-1) towards the second edge (216-2) to form the slanted profile.
 11. The formwork panel (200) as claimed in claim 10, wherein an angle of the slanted profile of the at least one stiffener profile (204) is selected such that any residual matter falling on the at least one stiffener profile (204) slides off of the surface (218).
 12. The formwork panel (200) as claimed in claim 11, wherein the angle of the slanted profile of the at least one stiffener profile (204) is selected from a range of 10° to 45°.
 13. The formwork panel (200) as claimed in claim 10, wherein the at least one stiffener profile (204) is a W-shaped profile.
 14. The formwork panel (200) as claimed in claim 10, wherein the at least one stiffener profile (204) is a V-shaped profile. 